Composite products



T. L. OBERLE ET AL COMPOSITE PRODUCTS 16 Sheets-Sheet 1 Original Filed Oct. 27, 1964 13 l| E m. :1 F \y; 2 Q E Q E @m 3 hm 3 2 HW i F El -|3 .r! l l s. Z 22 I TVN N,

INVENTORS TH aoooneL. OBERLE MAR|ON R. CALTON CALvm D. LoYD Z3, 3% ATT ORNEYS Nov. 21, 1967 T. L. OBERLE ET AL 3,353,935

COMPOSITE PRODUCTS Original Filed Oct. 27, 1964 16 Sheets-Sheet 2 INVENTORS. THEODORE L OBERLE MARION 52. CALTON CALVIN D. LOVD BY CLAUDEF W Nov. 21, 1967 T. L. OBERLE ET AL COMPOS ITE PRODUCTS Original Filed Oct. 27, 1964 0. wmO 07.530 0* n. OmO QZED... +0.0

16 Sheets-Sheet 5 0.0 0 0 00 000 00 000 0 00 000 00 00 0M 0.. Mm 000. %M m 0.0 0 0.0 000 0. 000 00 000 00 00. 0.. 0 0% 0 000. mmm m a 00 0 0 0 0 000 0. 0.0 0 0.0 0 000 0 000 00 3 0 0 00. 0 4. 0 00. w .0mm m 00 0 0 00 000 0. 0.0 0 000 0 000 0 00 0 00 3 mm 0.0z000fi w. 00z0-.0 0 r 000 0 0 0 000 0 000 0 0000 0.1 0 000 00 0 0% 6.0.1. Emma 62 mmmw 000 0 0 00 000 0. 000 0. 00 0 000 0 00 0. 000 .wwwmw 000. flfi ww 000. mmm 000 0 0 00 00 0 00 00.0 0 0 0 000 0 00 0 00 fi wm 0.00. 0 1 000. 0000 0 00 0.00 0. 0010 0000 0.0 0 00 0 00 .wfiww 000. 0.4 000. B 00 0 0. 000 0. 000 0 00 0.0. 0 00 0. 000 fi mfwm fi wa 0000 00 0 .00 000 0. 000 0. 00 0 00. 0 00 0. 000 M. 00.0 00.0 00 0 0 00 000 0. 00 0 0 0 0 0 000 0 00 0 00 0 000. 35% 000. 00 0 0 00 000 .0 000 00. 00 0 000 00 000. 00 0 0 00. 0 000. M 00 0 0 0. 000 0. 000 00. 0.0 000 000.0 0 0 000. fi mw 000. 3 00 0 0.0 00 0 00 000 00 00 000 00 000. 3 0 00. fi fim 0 00. 00 0 0 0. 000 0. 000 00 00 0 000 000 00 0 0.00. 0 0 00. 00 0 0 00 0.00 0. 00. 0. 00 0 000 0 00 0 00 E 0 1 0 00. 0 0 0.00. 00 0 0 00 00. 0. 000 0 00 0 000 00 0. 000 3 0% 0 00. fla 0.00. 00 0 0 0 00. 0. 000 0 00 0 000 0 00 0 00 3 000. 3. 0% 000.

Nov. 21; 1967 T. 1.. OBERLE ET AL I 3,353,935

COMPOSITE PRODUCTS IL QEIA;

IN ENTOR. .THEODORE L. BERLE MARION CALTON LoYo CLAUDE F. WHITE ATT'O EYS CALVIN Nov. 21, 1967 T. L. OBERLE ET AL 3,353,935

COMPOSITE PRODUCTS Original Filed Oct. 2'7, 1964 16 Sheets-Sheet 5 2? r 70 LBS. UPSET INVENTORS. THEODORE. L. OBERLE MARION l2. CALT ON CALVIN D. l o v D BY CEALiZEiQ/{W ATTORNEYS T. L. OBERLE ET AL Nov. 21, 1967 COMPOSITE PRODUCTS 16 Sheets-Sheet 6 lginal Filed Oct. 27, 1964 J. .lBA-

"L R 5 w lk m T Y m Ao m v CLW w RD A R NN wmvw ERLA HAAL TMCC BY 2x7 4 Nov. 21; 1967 'r. L. OBERLE ET 5 COMPOS IIE PRODUCTS Original Filed Oct. 2'7, 1964 16 Sheets-Sheet 7 E S mLN .m RO E mET T. O V Y T NOAOH .T I CLW A L m D m O E Dwwu WRLA HAAL, TMCC Nov. 21, 1967 'r. L. OBERLE ET AL COMPOSITE PRODUCTS 16 Sheets-Sheet 8 iginal Filed Oct. 27, 1964 Nov. 21, 1967 T. L. OBERLE ET AL COMPOS ITE PRODUCTS 16 Sheets-Sheet 9 Original Filed Oct. 27, 1964 E LN 8 %R0 E m TDT m WBLYI. w mW W/ T L YA RDF E mwmw VU .ORLA MAAL TMCC Nov.

T. L. OBERLE ET COMPOSITE PRODUCTS Original Filed Oct. 27, 1964 REV. PER. MIN.

TORQUE (FT. L55) HORSEPOWER /SQ. IN.

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TEMPERATURE (I-'3 PRESSURE (PSI) 16 Sheets-Sheet 10' Iis-eTaIonI'a TIME (sEc.)

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'TII EoooIzE L. OBERLE MARION I2. .QAETON CALVIN Lovo ATTORNEYS Nov. 21, 1967 T. L. OBERLE ET AL 3,353,935

COMPOSITE PRODUCTS 16 Sheets-Sheet 11 Original Filed 001;. 2'7, 1964 TORQUE HORSEPOWER PRESSURE INVENTOR. THEODORE L. OBERLE MARION R. CALTON CALVIN D. LOYD CLAUDE F. WHITE .1; .EEE.

ATTORNEYS Nov. 21, 1967 T. L. OBERLE ET 3,353,935

COMPOSITE PRODUCTS Original Filed Oct. 27, 1964 I 6 Shees-Sheet 12 PRIOR ART FRICTON WELDING PROCESS I PRESENT: lNvENTloNi INVENTORSV. THEODORE L. OBERLE ATTORNEYS LOYD F. WHI r INTERFACE MARION I2. CALTON CALVIN D.

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,IIIIIII ,IIIIIII DISTANCE FROM Nov. 21, 1967 T. L. OBERLE ET 3,353,935

COMPOSITE PRODUCTS 16 Sheets-Sheet 13 Original Filed Oct. 27, 1964 ATTORNEYS NOV. 21, 1967 QBERLE ET AL 3,353,935

COMPOSITE PRODUCTS Original Filed Oct. 27, 1964 l6 Sheets-Sheet 1L ElE 4.-U-

- INVENTORS. THEODORE L. 05521.2 MARION .C-ALTON ALVIN Lovo LAUDE F WHITE W4 i -q? p ATTORNEYS Nov. 21, 1967 "r. L. OBERLE ET AL 3,353,935

COMPOSITE PRODUCTS Original Filed Oct. 27, 1964 l6 et h et 16 v ENERGY LOW MEDIUM HIGH PRESSURE MEDIUM HIGH VELOCITY LOW MEDIUM HIGH F5 .4 5 I I U INVENTORS THEODORE L. OBERLE MARION R. CALTON CALVIN D. LOYD BY CLAUDE F. WHITE AT TORNEYS United States Patent $353,935 QOMPOSHTE PRODUCTS Theodore Loring Oberle, Washington, Marion Roy Calton, East Peoria, Calvin David Loyd, Peoria, and Claude Foster White, Creve Coeur, Ill., assignors to Caterpillar Tractor Co., Peoria, 111., a corporation of California Original application Oct. 27, 1964, Ser. No. 407,955, now Patent No. 3,273,233, dated Sept. 20, 1965. Divided and this application Jan. 12, 1966, Ser. No. 535,630

9 Claims. (Cl. 2?11) This is a division of application Ser. No. 407,955, filed Oct. 27, 1964, now Patent No. 3,273,233, which is in turn.

a continuation-in-part of application Ser. No. 212,178, filed July 9, 1962, now abandoned, which is in turn a continuation-in-part of application Ser. No. 146,710, filed Oct. 23, 1961, now abandoned.

This invention relates to process and apparatus for forming bonds in articles and to articles produced by the bonding process. The present invention has particular application to a process in which two or more members to be joined are engaged under pressure and the engaged surfaces are heated to a bonding temperature by friction and plastic working produced by relative motion at the engaged surfaces.

Until recent years the majority of metal joining processes having significant commercial application could be placed in one of three categoriespressure processes, including forging and resistance welding techniques such as upset and flash butt welding; non-pressure processes, also known generally as fusion welding, including arc and gas welding; and brazing processes. In the past few years a serious need has developed for both higher strength bonds and bonds between materials that have been difficult or impossible to bond by existing techniques. Thus, for example, one of the problems presented by are or gas welding is that of coarse grained and dendritic structures in the weld area which detract from the mechanical properties of the materials joined. Arc and gas welding are also limited to joining materials within a limited range of atomic diameters; a steel part cannot be joined to a titanium part because the difference in the atomic diameters is too great.

It is a primary object of the present invention to bond parts, including parts composed of dissimilar metals, metalloids and inorganics, with a bond that achieves the full strength of a parent part being joined. It is a related object to bond parts having large differences in atomic diameters.

One of the more important processes to which much attention has recently been given is the friction welding process. Some features of this process are quite old, but, largely as the result of recent Russian publications of Work attributed to V. I. Vill', new interest and activity are developing in the process. The friction welding process as employed in accordance with Russian teachings is a sequential process in which the parts to be joined are first engaged under pressure at a common interface and rotated relative to one another to bring the interface to a certain temperature level and to certain conditions of sliding friction at the interface. The rotation is then stopped as quickly as possible, usually by braking or by reversing the torque applied by an electric motor, to keep the rotating masses from breaking a bond after it is partly formed. An increased axial force is then applied to produce an upset pressure effective to squeeze out a substantial amount of flash at the interface area and to form the bond as the parts cool. As the parts to be bonded increase in size larger and heavier motors and associated drive equipment are required to furnish the power and 3,353,935 Patented Nov. 21, 1967 larger braking equipment and related control systems are needed to bring the parts to a stop.

In this friction welding process the heat is applied at a rate which permits a significant amount of the heat to dissipate into the parts beyond the immediate area to be bonded. As a result, it is difficult to form a strong bond to a part, such as a heavy steel plate, having a large mass near the interface for drawing heat quickly away from the interface. A certain amount of time is required to bring the rotating part or parts to rest before the upsetting pressure is applied, and the parts must therefore be heated above the required bonding temperature to allow for some cooling of the parts during the time that rotation is being stopped. As a result of the rate at which the heat is applied and the total amount of heat which is supplied, a considerable amount of each part is heated to a plastic state. The axial pressure needed to form the bond forces the plastic material radially outwardly from the interface area, producing a large amount of flash.

This is of course wasteful of material but is an unavoidable consequence of the manner of applying the heat and pressure. The upset or compacting pressure applied after stopping is used to squeeze out of the bond area the oxides that are produced by the relatively long period of heating at relatively high temperatures. The large amount of flash produced makes dimensional accuracy difiicult to maintain. The large amount of heat applied also caused grain growth with resulting loss of desired mechanical properties in the heat affected zone. In many cases it is necessary to heat treat the bonded parts to effect some refinement of the enlarged grain. The benefits which can be realized by heat treatment are limited, and even under the best of conditions such subsequent heat treatment often cannot restore or make up for all the mechanical properties lost in the heat affected zone.

The method of the present invention is essentially a single, continuous operation. Two or more parts to be joined are pressed together at an interface and moved relative to one another while the pressure of engagement is very rapidly built up to convert mechanical energy to heat at the interface. The rate of pressure build-up and application of the energy is so quick that the heat is concentrated at the interface with a steep temperature gradient on each side of the inter-face until the bond is formed. No auxiliary braking, sensing, limiting or compensating equipment or controls are required. Instead, a predetermined limited amount of energy is quickly imparted to the parts, and the resistance to plastic working developed at and adjacent the interface as the bond forms stops relative movement of the parts as soon as the input of energy ends.

The total energy needed to produce the bond is developed before the parts are engaged. The process can proceed to completion without the need to wait for development of more energy at any stage during the process.

The present invention concentrates a minimal amount of energy at the interface and thereby minimizes the extent of the areas heated to a plastic state and the time at a temperature at which grain growth can occur. This is accomplished by controlling the power input as well as the total amount of energy applied. By applying a small amount of energy quickly and under high pressure, the present invention also substantially excludes air and thereby minimizes the formation of oxides in the interface. What oxides do exist are dissolved or fragmented and dispersed through the interface and flash by the forces applied.

The amount of extruded material can be closely controlled and in many cases reduced to an insignificant amount or eliminated entirely. This in turn permits greatly improved dimensional control.

Because the heat is applied in a manner to concentrate the heat at the interface and prevent dissipation away from the interface until after the bond is formed, the bonding method of the present invention is not dependent on the mass of the part available to draw heat away from the bond zone so that articles of varied configuration can be readily bonded together. For example, a small stud can readily be bonded to a thick plate. A strong bond between two articles of this kind has been difficult to achieve with the prior art friction welding process.

The present invention makes it' possible to readily and economically join dissimilar materials. It is, therefore, practical to fabricate composite products having specific physical characteristics at the particular locations desired.

It is another object of the present invention not only to heat rapidly but also to cool the heat affected area rapidly. Use is made of the'relatively large mass of un heated area to extract heat very rapidly from the small mass of the heat affected zone after the bond is formed. Thus, the unheated mass effects a severe quench of the heated area without auxiliary cooling techniques. This is especially important in the case of steels, to produce structures having the improved mechanical properties obtained by severe quenching operations.

It is another object of the present invention to world the material participating in the bond right up to the time it is cooled to obtain a bonded product having distinct grainrefinement throughout the heat affected'zonel No subsequent heat treatment is needed. It is a related object to orient the material heated to a plastic state to obtain strength and fatigue resistance properties superior to those produced by existing bonding'te'chniques. This object is achieved by the'manner in'w'hich the heat and forces are applied. A bonded product produced by the present invention has a narrow heat affected zone, with refined grain throughout, and an abrupt transition between the displaced and non-displaced material.

In one embodimentof apparatus for practicing the" present invention, a selected amount of energy is" stored in a rotating inertial mass. This mass is located close to the interface and is rigidly associated with a part to be bonded to minimize elastic wind-up. Inertial masses elsewhere in the rotating system aremaintained'sufficient ly small in comparison to the control mass to prevent the inertia of such other masses from having a significant effect on the formation of the bond. The energy stored in the rotating mass supplies the heat energy for the" bond when two or more parts are engaged in rubbing contact under pressure at their interface The stored energy also produces extensive plastic working at low speed after the bond is formed. The size of the flywheel, pressure and rate of pressure build-up are selected to take the interface rapidly to and through an initial peak power input and to bring the interface to a plastic" condition. While the interface is in this plastic condition, the speed decreases to a critical speed'at which the interface can bond under the forces applied. The bond forms across the en'- tire interface as the speed of relative rotation drops to this critical speed. The bond is formed while the mass is still rotating and while a substantial amount of the stored energy is retained in the rotating mass. This remaining energy is put into the bond zone through rotational straining of the material in the bond zone and heavy plastic working. The intense local working produced by the resultant effect of torque and moderate load during rotation after the bond has formed forges the material in the bond area and ejects coherent flash from the bond zone to clean the bond zone and contributes beneficial characteristics to the bond area; This embodiment of the invention makes it possible to bond large parts with apparatus of low power since the energy can be accumulated in the rotating mass. A method and apparatus using an inertial mass fi i g 9 l Qi Q i 4, this manner to produce the results described constitute further objects of the present invention.

Other and further objects of the present invention will be apparent from the following description and claims and are illustrated in the accompanying drawings which, by way of illustration, show preferred embodiments of the present invention and the principles thereof and what are now considered to be the best modes contemplated for applying these principles. Other embodiments of the invention embodying the same or equivalent principles may be used and structural changes may be made as desired by those skilled in the art without departing from the present invention and the purview of the appended claims.

In the drawings:

FIG. 1 is a front elevational view, partially broken away in parts to show details of construction, of one embodiment of apparatus constructed in accordance with and effective to perform the present invention;

FIG. 2 is an elevation view of an inertial weight, with a portion shown in section, used in the apparatus shown in FIG. 1;

'FIG. 3 is an elevation view, partially broken away in parts, of another embodiment of apparatus constructed in accordance with and' effective to perform the present invention;

FIG. 4 is a chart giving data for forming bonds in accordance with the present inventionwith the materials and part sizes listed;

FIGS. 5A and 5B are exterior views of products bonded by the prior art friction process and the present invention, respectively;

FIGS. 6A and 6B are exterior views of the products shown in FIGS. 5A and 53, respectively, but with the flash removed and etching applied to show the relative width ofthe heat affected'zones;

FIGS. 7A and 7B' are'vie'ws of etched cross sections of the products shown in FIGS. 5A and 5B, respectively, and show the heat affected zones;

FIGS. 8A and 8B are exterior views of the products shown in FIGS. 5A and 5B, respectively, but with the flash removed and the surfaces deep etched to show the reorientation of material heated to a plastic state during thebonding operation;

FIGS. 9 and 10 are views of etched cross sections of products produced by the present invention and illustrate the progression of the bond across the interface;

FIGS; 11A through 11D are views of etched cross sections of products formed by this invention and illustrate the results of variations in the speed of rotation and pressure applied to effect the bond;

FIG. 12is a view of an etched cross section of a product produced in accordance with the present invention and illustrates the results of applying energy significantly in excess of that required to form the bond;

FIGS. 13A and 13B are views, enlarged six times, of deep etched cross sections of products bonded by the prior art friction process and the present invention, respectively, and illustrate the heat affected zone and the reorientation of material heated to a plastic state;

FIG. 14 is a photomicrograph, enlarged seventy-five times and taken on a plane inclined 10 from the plane of the interface, of a deep etched cross section of a product bondedin accordance with the present invention, and illustrates the sharp change in the direction of flow lines;

FIG. 15A is a photomicrograph, enlarged seventy-five times, of an etched cross section of a product bonded by the prior art friction process and illustrates the parent grain structure in the non-heat affected zone;

FIG. 15B is a photomicrograph like FIG. 15A but taken in the heat affected zone near the outer boundary of the heat affected zone;

FIG. 15C is'a photomicrograph like FIG. 15A but taken from a part of the heat afiected zone where grain growth has occurred;

FIG. D is a photomicrograph like FIG. 15A but taken at the interface;

FIG. 16 is a photomicrograph, enlarged seventy-five times, of an etched cross section of a product bonded in accordance with the present invention and shows the entire width of the heat affected zone;

FIG. 17 is a photomicrograph, enlarged fifteen hundred times, of an etched cross section of a product bonded by the prior art friction technique and is taken near the boundary of the heat affected zone;

FIG. 18 is a photomicrograph, enlarged fifteen hundred times, of an etched cross section of a product bonded in accordance with the present invention and is taken near the boundary of the heat affected zone;

FIG. 19 is a photomicrograph, enlarged fifteen hundred times, of an etched cross section of a product bonded by the prior art friction welding process and is taken near the interface;

FIG. 20 is a cross section view, enlarged fifteen hundred times, of an etched cross section of a product bonded in accordance with the present invention and is taken near the interface;

FIGS. 21 and 22 are photomicrographs, enlarged onev hundred and five hundred times, respectively, of an etched cross section of an SAE8630 (dark)GMR235 (light) steel nickel alloy product bonded in accordance with the present invention and illustrate the absence of fused material at the solid-state boundary formed at the interface;

FIG. 23 is a photomicrograph, enlarged one hundred times, showing the clean bond obtained in highly receive materials (here titanium) bonded in accordance with the present invention;

FIG. 24 is a photomicrograph, enlarged five hundred times, of an aluminum-bronze alloy and steel product bonded in accordance with the present invention;

FIGS. 25A through 25B are plots comparing various parameters against time for the prior art friction technique (broken lines) and the present invention (solid lines);

FIG. 26 is a plot, on one chart, of the various parameters plotted individually in FIGS. 25A through 25E;

FIG. 27 is a plot, on an expanded time scale, of various parameters versus time for the process of the present invention;

FIG. 28A is a photomicrograph, enlarged one hundred times, of the interface zone of a bond in SAE 1018 steel parts subjected to high torque and rotational plastic working after the bond formed;

FIG. 28B is a photomicrograph, enlarged one hundred times, of the interface zone of a bond in SAE 1018 steel parts formed under the same conditions as the bond shown in FIG. 28A except for the elimination of substantially all torque and rotational plastic working after the bond formed;

FIG. 29 is a comparison plot of temperature versus distance along the longitudinal axis of a product bonded by the prior art friction process and a product bonded by the present invention;

FIG. 30 is an isometric view of a product formed by bonding studs to a heavy plate in accordance with the present invention;

FIG. 31 is a fragmentary view in section of a high temperature alloy turbine wheel bonded to a heat insulating washer which is in turn bonded to a low alloy shaft in accordance with the present invention;

FIG. 32 is an enlarged fragmentary view in section of the union between the turbine wheel, washer and shaft of FIG. 31 before the shaft and washer are turned down to the final outside diameter;

FIG. 33 is an enlarged fragmentary view of an etched cross section of the low strength heat insulating Washer bonded to the high strength turbine wheel of FIG. 31;

FIG. 34 is a plan view of an aluminum piston having a steel heat plug bonded to the piston;

FIG. 35 is a fragmentary cross section view taken along the line indicated by and in the direction of the arrows 35-35 in FIG. 34;

FIG. 36 is a fragmentary cross section view illustrating the method and apparatus for bonding the heat plug to the piston shown in FIG. 34;

FIG. 37 is an isometric view of a heat plug prior to being bonded to the piston in FIG. 34;

FIG. 38 is an enlarged fragmentary cross section view of a portion of the heat plug and illustrates the manner in which tabs of the heat plug can be undercut to shear at a certain torque level during the bonding operation;

FIG. 39 is a fragmentary view taken along the line indicated by and in the direction of the arrows 3939 in FIG. 36;

FIG. 40 is a fragmentary elevation view of a flexible follower which can be used in apparatus of the present invention to facilitate alignment of the parts to be bonded;

FIG. 41 is a fragmentary elevation view, partly broken away in section, illustrating the use of a ceramic collar and a ceramic insert plug for smoothing flash forward during the bonding operation;

FIG. 42 is an isometric view of a product produced by the use of a ceramic collar and insert plug as illustrated in FIG. 41;

FIG. 43 is a plot of the torque and power curves for a typical bond cycle with steel bars and shows the three stages of the process of the present invention;

FIG. 44 is a chart showing upper and lower limits on the initial speed for different size steel bars; and

FIG. 45 shows bond patterns for various energy, load and speed conditions.

In FIG. 1 apparatus constructed in accordance with one embodiment of the present invention is shown as a machine having a frame like that of a lathe with a bed 10 having a headstock 11 at one end and a tailstock in the form of spaced bearings 12 and 13 at the other end. A headstock spindle 14 is rotatable in bearings 16 and 17 and carries a chuck 18 at one end. The chuck 18, herein shown as a collet chuck, may be of any suitable type depending upon the workpiece to be held. A motor 19 drives the headstock spindle through conventional belt and pulley means including a pulley 21 keyed to the spindle. The tailstock bearings 12 and 13 support a reciprocable tailstock spindle 22 keyed against rotation in one of the bearings as illustrated at 23. This spindle carries a chuck 24 herein shown as a face or jaw-type chuck which, again, may be of any suitable type depending upon the nature of the workpiece to be held thereby.

The tailstock spindle is advanceable toward the headstock spindle by means herein shown as a lever 26 pivotally supported with respect to the machine bed at 27 and having a forked upper end embracing pins, one of which is shown at 28 on the spindle. Advancing of the tailstock spindle can be accomplished with any suitable power means herein illustrated as a pneumatic roto-chainher 29 suitably supported beneath the bed of the machine and adapted to be activated in a well known manner by controls (not shown) for charging it with air under pressure from a suitable source of supply.

The headstock spindle is provided with an inertial mass generally indicated at 31 which may be in the form of a plurality of disc-like weight removably secured against rotation with respect to the spindle. An example of one of such weights is shown in FIG. 2 wherein it is illustrated as formed in separable halves adapted to be secured together as by cap screws 32 and having a keyway 33 for reception of a key shown at 34 in FIG. 1 which fits within a suitable key slot in the headstock spindle.

In practicing the invention, a workpiece such as shown at 35 is held in the headstock chuck and a workpiece 36 is held in the tailstock chuck. To bond the workpieces together, the motor 19 is started to bring the headstock spindle 14 and inertial mass 31 thereon to a predetermined speed of rotation, the value of which depends upon the size and shape of the parts to be bonded, their compositionand'the Weight of the inertial mass. The roto-chamber 29 is then activated to bring the stationary workpiece 36 intoconta'ct with the rotating workpiece 35 withsuffic'i'e'nt force't'o bring the partsto bonding temperature due to friction at the engaging surfaces of the workpieces and t6 supply-upsetting pressure at the same time as'the inertial mass expends its energy and rising tor'que extrudes flash and the headstock spindle comes to rest; At this time, a'bon'd is-form'e'd between'the workpieces, pressure in the roto-chamber is relieved and the bonded workpieces are removed'frorh the chucks.

Due tothe fact thatthe' motor is not relied upon for imparting'rotation to one of theworkpiece while it is in frictional contact under pressure with the other workpiece, a relatively high-speed of-rotation can be obtained with-ave'ry small'motbr and this high speed of the parts which include the inertial mass produces bonding temperatures in a remarkably short period of time. Because of the variation in the size and nature of the material or parts to be bonded, the speed'of rotatiointhe weight and radius of gyration of the ine'rtial'mass and the pressure between the partsis calculated for each different type of bond'to be made. The following is an example of conditions which will product a perfect bond between twosteel rods of one inch diameter:

Speed r.p.m 2,000 to 3,000 Pressure p.s.i 8,000 to 12,000 Inertial mass lbs 80 The bond formed in accordance with the above described method and between the ends of two one-inch steel bars is produced in approximately one second of frictional contact time as compared'to thirty seconds or longer in the prior art friction welding methods. This short duration of the heating cycle reduces distortion of the parts being bonded, thus reducing subsequent machining of flash. It also eliminates grain growth which results from a longer heating cycle. Due to the shortness of the heating'cycle, the time for conduction of heat away from the interface prior to formation'of the bondis so limited that a rod-like part may be bonded to a plate or other large part of any thickness. Furthermore, a clean bond is formed because the limited heating cycle and high pressures employed minimize oxidation or inclusion in the heated metal and this results in'a minimum of flashed or extruded metal so that dimensional control is improved and waste material is held to a minimum. The use of this inertial process also eliminates the need for a complicatcd control system which is required in the prior art friction welding processes to control and sequence the time of friction-rubbing, to alter the upset pressure and disengage the clutchand apply the brake.

In the present method it is even unnecessary to stop the motor as it will be stalled by the frictional drag and the formation of the weld. It is of course possible however, to de-energize the motor automatically when the inertial mass attainsa desired speed and other automatic controls may be added to the apparatus herein disclosed depending upon the size and type of parts being welded.

While the inertial mass is illustrated as having parts separable from the headstock spindle, it may be a single fixed weight where a machine is used for welding only one combination of parts. In some cases, as with small parts, the weight of the spindle and chuck may sufiice,

and in other cases, a larger or weighted chuck may serve as the mass.

In FIG. 3 another embodiment of a machine constructed in accordance with the present invention is indicated generally by the reference numeral 46. In this instance the machine 46 is similar to a conventional press and is adapted to be semi-automatic in operation. The machine 46 includes four rectaugularly spaced posts 47 extending upwardly from a machine base 48 to support a work table 49 and a rigidly secured head 51. A movable press head 52 is slidably supported on posts 47 intermediate the work table 49 and the upper head 51.

The ma'chin'e46 is'shown in FIG. 3 with the operating parts in the positions they occupy just prior to the application of bonding forces to two parts to be joined. A workpiece 53'is" clamped in a lower chuck 56, after a finished article has been removed from this chuck at the conclusion of a preceding bonding operation. A tie bar 57iex'tends' downwardly from the chuck 5 6' through a spindle 58 journalled for rotation in bearings 59. The lower end of the tie bar 46 is rotatably mounted within a collar 61 which is moved up and down by a jack 62 through a lever 63. Retraction of the jack 62 clamps the workpiece 53 within the chuck 56 while extension of the jack 62 releases the workpiece. A microswitch 64 is positioned to be closed on retraction of the jack 62.

The machine 46 includes means for developing a controlled limited amount of energy to be applied as heat at the interface of the workpieces, and these means comprise a hydraulic motor 66 connected to drive the spindle 58' through gears 67, together with weights 68 rigidly secured for rotation with the chuck 56 by bolts 69. It is also'desirable that the weights 68 be positioned closely adjacent the interface to minimize problems of elastic wind-up.

A workpiece 54 is clamped in an upper chuck 71 by a jack 72 having an enlarged head 73 formed with an inclined ramp 74 effective to raise a roller 76 and lever 77 about'pivot 78 when the jack 72-is extended; A microswitch 79'is mounted adjacentthe head'73 and is closed when the jack 72 is retracted In this instance the chuck 71' is non-rotatably mounted in the movable head 52; The vertical position of the head 52 is under the control of two in line jacks 81 and 82, which when extended" as described below, serve as means forconverting the energy stored in the rotating weights 68 to heat a't'the interface of the workpieces 53' and 54.

The machine 4-6 includes means for controlling the time heat is applied to the interface to form the bond substantially simultaneously with the ending of the heat input; These control means include a tachometer 83 for sensing the speed of rotation of the chuck 56 and' workpiece 53 and a pressure regulating valve 84 for controlling the pressure with which the workpieces 53 and 54 are engaged under the control of the jacks 81 and 82.

A series of control buttons 86, 87' and 88'are disposed near the work table 49 and* are effective in combination with'the' pres'sureregula'tor 84 and speed sensing tachometer 83, to coordinate the application of the energy stored in the" rotating weights 68' with the axial force exerted by the jacks 81 and 82'.

In'operation, and with the parts disposed in the positions illustrated'in FIG: 3 at the conclusion of a bonding operation, the operator first inserts a workpiece 54 in the chuck 71 and pushes button 88 to extend the jack 72 and clamp the workpiece in the chuck 71. Pushing button 88" also extends jack 62- to unclamp chuck 56 clamp the new workpiece in the chuck. Retraction of the jack 62 closes microswitch 64-which energizes a solenoid (notillustrate'd) to direct fluidto motor 66'to start rotation of the spindle 58, chuck 56', Weights 68 and workpiece 53. The closing of microswitch 64 also directs fluid to the upper jack 81 to extend this jack. When the jack 81 is fully'e'xtended, the workpieces 53 and 54 are separated by about one-half inch. As soon as the spindle 58 reaches a predetermined speed corresponding to the desired' amount of energy to be imparted to the workpieces 53 and 54, the tachometer 83 de-energizes the solenoid supplying fluid to the motor 66, at which time the motor 66 free-wheels, and directs fluidto the 

1. A COMPOSITE PRODUCT COMPRISING TWO METAL PARTS BONDED TOGETHER ACROSS A GENERALLY CIRCULAR COMMON INTERFACE AND INCLUDING A NARROW ZONE OF MATERIAL EXTENDING FROM THE INTERFACE INTO AT LEAST ONE PART AND COMPOSED OF SPIRALLY DISPLACED MATERIAL HEATED TO A PLASTIC CONDITION BY ROTATIONAL RUBBING CONTACT OF THE TWO PARTS DURING THE BONDING PROCESS AND ENDING IN AN ABRUPT TRANSITION TO MATERIAL OF THE PARENT PART NOT DISPLACED BY THE BONDING PROCESS, AT LEAST ONE PART HAVING A GENERALLY CIRCULAR SHAPE AT THE INTERFACE WHICH PERMITS ROTATIONAL MOTION WITHOUT EXPOSING SUBSTANTIAL PORTIONS OF THE INTERFACE DURING ROTATION, ALL OF THE MATERIAL IN SAID NARROW ZONE HAVING GRAIN WHICH IS BOTH EXTENSIVELY DISPLACED IN A SPIRAL DIRECTION AND REFINED BY THE LAST FEW TURNS OF PLASTIC FORGING PRODUCED IN THE ZONE AS THE RESISTANCE TO TWISTING DEVELOPED IN THE PLASTIC MATERIAL SLOWS THE ROTATION TO A STOP. 